Prediction of dimension error based on the deflection of cutting tool in micro ball-end milling

Micro milling forces can easily induce bending deflection when machining micro complex components, which makes the tool center deviate the desired trajectory and causes dimension error. So this study is mainly focused on analysis of dimension error in micro ball end milling. The analytical prediction model of dimension error is proposed based on the deflection of micro ball-end milling cutter induced by micro milling forces, which referenced to Euler Bernoulli cantilever beam equations. The micro milling forces acting on ball end milling cutter can be acquired by numerical integration. And the proposed models using two-section and three-section cantilever beam equation separately were analyzed by comparison. The proposed machining deflection’s error prediction model is validated by micro ball end mill on stainless steel workpiece. The experimental results show that the model based on three-section cantilever beam equation has a better correlation with the simulation results. The proposed theoretical model offers a basis for controlling machining deflection as well as manufacturing process optimization.